Installation Procedure

WARNING: This page is about a different variant/trim than selected.

NOTE: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak.

NOTE: Refer to Fastener Notice .

Fig 1: View Of Left Fuel Injector Pipes

Courtesy of GENERAL MOTORS CORP.

Install the fuel injector pipes.
Tighten: Tighten the fittings to 41 N.m (30 lb ft).
After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
Install the PCV hose/pipe. Refer to Crankcase Ventilation Hoses/Pipes Replacement .
Connect the glow plug control module electrical connectors (1, 2).

Fig 2: Connecting Glow Plug Control Module Electrical Connectors
Courtesy of GENERAL MOTORS CORP.
Install the auxiliary generator, if equipped. Refer to Generator Replacement - Auxiliary (6.6L (LLY) Engine) .
Install the water outlet tube. Refer to Water Outlet Tube Replacement (6.6L (LLY) Engine) .

Fig 3: View Of Main Electrical Connector Harness Bracket & Bolts

Courtesy of GENERAL MOTORS CORP.

Install the engine harness main connector bracket bolts.
Tighten: Tighten the bolts to 21 N.m (15 lb ft).
Connect the barometric sensor electrical connector.
Install the engine harness main electrical connectors bolts.

Fig 4: View Of Main Engine Electrical Harness Connector Bolts
Courtesy of GENERAL MOTORS CORP.

Tighten: Tighten the bolts to 10 N.m (89 lb in).
Connect the main engine electrical harness connectors.

Fig 5: View Of Main Engine Electrical Harness Connector Latches & Harness Clip
Courtesy of GENERAL MOTORS CORP.
Push down on the latches (1) in order to connect the connectors.
Close the harness clip (2).

Fig 6: View Of Fuel Line Bracket & Nut

Courtesy of GENERAL MOTORS CORP.

Install the fuel line bracket to the stud.
Install the fuel line bracket nut.
Tighten: Tighten the nut to 21 N.m (15 lb ft).
Connect the fuel lines. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
Position the generator positive cable.
Install the generator positive cable in the clip on the engine front cover.
Install the generator positive cable and nut to the generator.
Tighten: Tighten the nut to 9 N.m (80 lb in).
Install the battery positive cable junction block bracket and bolt (1) to the power steering bracket.

Fig 7: View Of Battery Cable Junction Block Bolt At Power Steering Pump Bracket
Courtesy of GENERAL MOTORS CORP.

Tighten: Tighten the bolt to 9 N.m (80 lb in).
Remove the tape from the turbocharger openings.
IMPORTANT: Lubricate the end of the duct prior to installation.
Install the charged air cooler inlet duct connector (4) to the turbocharger.

Fig 8: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
Courtesy of GENERAL MOTORS CORP.
Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).
Tighten: Tighten the clamp to 6 N.m (53 lb in).
Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
Fill the cooling system. Refer to Draining and Filling Cooling System (w/RPO HP2) or Draining and Filling Cooling System (w/o RPO HP2) .
Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) .
Prime the fuel system. Refer to Fuel System Priming .
Start the engine. If the engine stalls, repeat the above step.
Once the engine starts, inspect for fuel leaks.